Shower floor installation method and system

ABSTRACT

A method to install a shower floor includes the initial step of installing a drain conduit, after which a molded foam base is positioned over the drain conduit. A primary drain component is installed over the drain conduit and a spacer is secured to a flange on the primary drain component. Drainage openings are formed in the spacer. Flooring is laid on the foam base. Shims are applied to the spacer until the uppermost shim is flush with the flooring. A drain cover is mounted on the uppermost shim.

This application claims priority based on provisional patent application Ser. No. 62/071,235, filed Sep. 17, 2014.

This invention relates to bathroom plumbing systems and methods of installing the same.

More particularly, the invention relates to the installation of a shower floor.

Those of skill in the art have long endeavored to provide improved apparatus and methods to install a shower floor.

Accordingly, it would be highly desirable to provide such improved apparatus and methodology.

Therefore, it is a principal object of the invention to provide an improved method and apparatus for installing the floor of a shower.

These and other and further objects of the invention will be apparent to those skilled in the art from the following detailed description thereof, taken in conjunction with the drawings, in which:

FIG. 1 is a perspective view illustrating a shower floor with an opening formed therein and illustrating the end of a hollow drain conduit extending upwardly into the opening in the shower floor;

FIG. 2 is a perspective view illustrating an internally and externally threaded primary component of a drain assembly to be installed in the shower floor opening of FIG. 1;

FIG. 3 is a perspective view illustrating a pliable compressible polymer cylindrical seal which is installed on the interior of the primary drain assembly component of FIG. 2;

FIG. 4 is a perspective view illustrating an internally threaded locking member which threads on to the lower end of the primary drain assembly component of FIG. 2 and is utilized to secure the primary drain assembly component of FIG. 2 in the shower floor opening of FIG. 1;

FIG. 5 is a perspective view illustrating an externally threaded drain assembly component which is turned into the internally threaded interior of the primary drain assembly component of FIG. 2 to compress and secure the seal of FIG. 3 in the primary drain assembly component;

FIG. 6 is a perspective view illustrating the installation of a spacer ring on the top of the primary drain assembly component of FIG. 2;

FIG. 7 is a perspective view illustrating a shim utilized in conjunction with the drain assembly apparatus of FIG. 2;

FIG. 8 is a perspective view illustrating another shim utilized in conjunction with the drain assembly apparatus of FIG. 2;

FIG. 9 is a top view illustrating a grate utilized in conjunction with the drain assembly of the invention; and,

FIG. 10 is a bottom view of the grate of FIG. 9 illustrating further construction details thereof.

Briefly, in accordance with the invention, provided is an improved method to install a shower floor.

The method comprises the steps of installing a drain conduit having an upwardly projecting cylindrical open end; and, providing a cylindrical primary drain component. The primary drain component includes a top with an outwardly extending flange; a bottom; and, an internally threaded inner cylindrical opening. The internally threaded inner cylindrical opening extends from the top toward the bottom, is shaped and dimensioned to receive the upwardly projecting end of the conduit such that the end is spaced apart from and concentric with the inner cylindrical opening, and, includes a circular inwardly projecting seating flange. The primary drain component also includes an externally threaded outer cylindrical surface extending from the top to the bottom.

The method also includes the step of molding a polymer foam base with an upper surface, a lower surface, and an opening formed therein to fit over and receive the externally threaded outer cylindrical surface of the primary drain component.

The method further comprises the steps of inserting the primary drain component in the opening in the polymer foam base; providing an internally threaded locking member; threading the locking member on the bottom of the primary drain component and against a portion of the polymer foam base to secure the primary drain component in the opening in the polymer foam base; installing the polymer foam base such that the open end of the drain conduit upwardly extends into the internally threaded inner cylindrical opening of the primary drain component; providing a hollow cylindrical pliable polymer sleeve shaped and dimensioned to fit intermediate the internally threaded inner cylindrical opening of the primary drain component, and the drain conduit; installing the polymer sleeve intermediate the drain conduit and the internally threaded inner cylindrical opening.

The method further comprises the steps of providing a hollow externally threaded compression member shaped and dimensioned to turn into the internally threaded inner cylindrical opening of the primary drain component; and, turning the compression member into the internally threaded inner cylindrical opening of the primary drain component to contact and compress the polymer sleeve between the drain conduit and the internally threaded inner cylindrical opening of the primary drain component.

The method still further comprises the steps of providing at least one hollow cylindrical spacer with at least one drainage opening formed therein; securing the spacer to the flange of the primary drain component; applying flooring to the upper surface of the base; providing at least one hollow cylindrical shim; securing the shim to the spacer to compensate for the thickness of the flooring; providing a perforated drain cover; and, mounting the drain cover on the shim.

Turning now to the drawings, which depict the presently preferred embodiment of the invention for purpose of illustration thereof and not by way of limitation of the scope of the invention, and in which like reference characters refer to corresponding elements throughout the several views, one preferred embodiment of the invention is an improved method of installing a shower floor.

The first step in the improved method consists of installing a drain conduit having an upwardly projecting cylindrical open end 14 (FIG. 1 and FIG. 2). The conduit typically leads from the cylindrical open end into the ground (or through a building structure) and to a septic tank or municipal sewer system. The open end of the conduit is intended to receive and drain water which is dispensed into a shower by a shower head. End 14 extends a selected distance above the ground on which a polymer foam base 10 will eventually be placed.

The next step in the method of the invention consists of providing a cylindrical primary drain component 20. Component 20 includes a top 21 with an outwardly extending flange 23, a bottom 22, an internally threaded inner cylindrical opening 26 extending from the top 21 toward bottom 22. Opening 26 is shaped and dimensioned to receive the upwardly projecting end 14 of the conduit such that end 14 is spaced apart from and concentric with inner cylindrical opening 26 in the manner illustrated in FIG. 2. Opening 26 also includes at bottom 22 a circular inwardly projecting seating flange 24 (FIG. 2). Component 20 also includes an externally threaded outer cylindrical surface 27 extending from top 21 to bottom 22.

Molding a polymer foam base comprises the next step in the method of the invention. The base 10 (FIG. 1) includes an upper surface 11, a lower surface 12, and an opening 13 formed therethrough to fit over and receive the externally threaded outer cylindrical surface 27 of the primary drain component 20. Any desired conventional or other method can be utilized to mold or otherwise form base 10. The presently preferred method consists of making a mold, preparing one or more liquid molding compositions, pouring the molding compositions into the mold, and allowing the molding compositions to expand and harden.

The next step consists of inserting the bottom 22 of primary drain component 20 in opening 13 in polymer foam base such that flange 23 rests on a portion of upper surface 11 that circumscribes opening 13. If desired, the portion of upper surface 11 which circumscribes opening 13 can be inset to facilitate the seating of flange 23 on surface 11.

An internally threaded 43 cylindrically shaped locking member 40 (FIG. 4) is provided in the next step in the method of the invention, after which locking member 40 is threaded onto bottom 22 and the lower portion of externally threaded outer surface 27 of primary drain component 20 such that the upper surface 42 of flange 41 of member 40 contacts and presses against a portion of lower surface 12 of foam base 13, and, such that flange 23 is seated on and pressed against upper surface 11.

The next step in the method of the invention consist of installing the polymer foam base on the ground around end 14 such that end 14 of the drain conduit upwardly extends into and is centered in the internally threaded inner cylindrical opening 26 of primary drain component 20. As shown in FIG. 2, when end 14 is positioned within opening 26, it is concentric with opening 26 and there is a space 25 between end 14 and opening 26.

A hollow cylindrical pliable polymer sleeve 30 is provided in the next sequential step of the method of the invention. The sleeve 30 is shaped and dimensioned to fit slidably in space 25 intermediate the internally threaded inner cylindrical opening 26 and end 14.

The next step in the method of the invention comprises slidably downwardly installing polymer sleeve 30 (FIG. 3) in space 25 intermediate end 14 and internally threaded inner cylindrical opening 26 such that lower edge 32 rests on seating flange 24.

In the next sequential step in the method, a hollow externally threaded 51 compression member 50 (FIG. 5) is provided. Member 50 is shaped and dimensioned to turn into internally threaded inner cylindrical opening 26 of primary drain component 20, and, to move downwardly into space 25. When member 50 is threaded in opening 26 and into space 25, lower circular edge 53 bears against upper edge 31 of member 30 and compresses member 30 between edge 53 and flange 24 such that at least a portion of inner surface 38 is pressed against end 14 and at least a portion of outer surface 34 (FIG. 3) of member 30 presses against opening 26. Notches 54, 55 in member 50 facilitate the use of a tool having teeth which engage notches 54, 55 so that the tool can be used to turn member 50. At least a portion of inner surface 52 of member 50 is, when member 50 is turned into space 25, adjacent end 14. The external threads 51 engage the threads formed in opening 26.

The next step in the method comprises rotatably turning compression member 50 into opening 26 so that at least a portion of member 50 extends into space 25 and compresses member 30 in the manner described in the preceding paragraph. Member 50 compresses member 30 between edge 53 (FIG. 5) and flange 24 (FIG. 2).

In the next step of the method of the invention, at least one hollow cylindrical spacer 60 is provided.

The following step in the method comprises securing with adhesive spacer 60 on flange 23 in the manner illustrated in FIG. 6. Apertures (not visible) are drilled through spacer 60 and through flange 23. The apertures 28, 29 (FIG. 2) drilled through flange 23 are internally threaded such that externally threaded screws 64, 65 (FIG. 6) can be turned through apertures in spacer 60 and into apertures 28, 29 and to secure spacer 60 in place on flange 23. Each aperture formed in spacer 26 is in registration with a different associated internally threaded aperture 28, 29. After spacer 60 is secured on flange 23 with screws 64 and 65, notches 61, 62, 63 are cut in spacer 60 to function as drain openings in the event water penetrates the periphery of spacer 60 or other exterior portions of the drain assembly. If water does penetrate the periphery of spacer 60, it can flow through notches 61 to 63 and into the drain in the manner illustrated by arrows A and B in FIG. 6. Before notches 61 to 63 are cut, spacer 60 has a continuous circular shape comparable to the shape of shims 70 and 80 (FIGS. 7 and 8). Spacer(s) 60 can be secured on flange 23 using any desired securing methodology and apparatus. Notches can be cut in and sections removed from spacer 60 before spacer 60 is secured to flange 23 so that the resulting short segments or pieces of spacer 60 can be secured to flange 63 in the configuration illustrated in FIG. 6 and it is not necessary to cut notches 61 to 62 after spacer 60 is applied to flange 23.

The next step in the method of the invention comprises applying ceramic tile 15, 16 or other flooring to upper surface 11 (FIG. 1) of base 10. The flooring extends adjacent to and circumscribes spacer 60. The upper or top surface of the flooring is above spacer 60. The distance which the upper surface of tile 15, 16 is above spacer 60 will vary depending on the thickness of the tile 15 (or other flooring), and of the Quik-Set™ cementitious material, of the adhesive, or of other material used to secure tile 15 to surface 11.

Since the upper surface of tile 15, 16 is higher than spacer 60, the next step in the method of the invention is to provide at least one hollow cylindrical shim 70, 80 (FIGS. 7 and 8). Typically, a selection of at least several shims of varying thicknesses is provided. Shim 80 is, for example, thicker than shim 70. One or more shims are secured with adhesive or other means to the top of spacer 60 such that the upper surface of the shim is substantially flush with the upper surface of tile 15, 16; or is located a selected distance above or below the upper surface of tile 15, 16. Since spacer 60 typically is comprised of a polymer (but can be comprised of any desired material), and since shim 70, 80 are also typically comprised of a polymer (but can be comprised of any desired material), an adhesive is typically utilized to secure shims 70 and 80 to the top of spacer 60 and, if necessary, to each other. The outside and inside diameter of each shim 70, 80 is preferably—but not necessarily—equivalent to the inside diameter (ID) and outside diameter (OD) of spacer 60 and a shim 70, 80 is, when glued or otherwise fastened to spacer 60, in registration with spacer 60. If shim 70 is utilized, the lower surface 71 is adhered to the top of spacer 60. If shim 80 is utilized, the lower surface 81 is adhered to the top of spacer 60. If shim 80 is utilized on top of and in addition to shim 70, lower surface 81 is adhered to top surface 72 of shim 70, and so on. Cylindrical, hollow shim 80 includes upper surface 82.

After shims 70, 80 are provided in accordance with the preceding paragraph, the next step in the method of the invention is to secure one or more shims to spacer 60 such that the uppermost surface 72, 82 of the last shim applied is substantially flush with the upper surface of tile 15, 16. Shim 70, 80 is applied to spacer 60 so shim 70, 80 is in registration with spacer 60

In accordance with the next step of the invention, a perforated drain cover 90 is provided (FIGS. 9 and 10). Perforations, or drain openings, 91 and 92 are formed through cover 90. Cover 90 includes top surface 93 and bottom surface 94. As can be seen in FIG. 10, feet 95, 96, 97, 98 extend outwardly from bottom surface 94. Feet 95 to 98 frictionally fit into and engage the cylindrical inner surface 73, 83 of a shim 70, 80 that cover 90 can be secured in place on spacer 60.

The final step in the aforementioned method of the invention is to install cover 90 by pressing feet into a shim 70, 80 to frictionally engage an inner surface 73, 83. Any desired procedure or cover 90 structure can be utilized to facilitate securing cover 90 in place above a shim 70, 80, or, in the event a shim 70, 80 is not required, above spacer 60. If after, cover 90 is installed, the shower in which the shower floor is installed is used, water drains from the shower floor through openings 91 and 92, into the open end 14, and out through the drain conduit to a sewer system or septic tank.

Having described my invention in such terms to enable those of ordinary skill in the invention to make and use the invention, 

I Claim:
 1. A method to install a shower floor comprising (a) installing a drain conduit having an upwardly projecting cylindrical open end; (b) providing a cylindrical primary drain component including (i) a top with an outwardly extending flange, (ii) a bottom, (iii) an internally threaded inner cylindrical opening extending from said top to said bottom, said opening shaped and dimensioned to receive said upwardly projecting end of said conduit such that said end is spaced apart from and concentric with said inner cylindrical opening, and including a circular inwardly projecting seating flange, and (iv) an externally threaded outer cylindrical surface extending from said top to said bottom; (c) molding a polymer foam base with (i) an upper surface, (ii) a lower surface, and (iii) an opening formed therein to fit over and receive said externally threaded outer cylindrical surface of said primary drain component; (d) inserting said primary drain component in said opening in said polymer foam base; (e) providing an internally threaded locking member; (f) threading said locking member on said bottom of said primary drain component and against a portion of said polymer foam base to secure said primary drain component in said opening in said polymer foam base; (g) installing said polymer foam base such that said open end of said drain conduit upwardly extends into said internally threaded inner cylindrical opening of said primary drain component; (h) providing a hollow cylindrical pliable polymer sleeve shaped and dimensioned to fit intermediate (i) said internally threaded inner cylindrical opening of said primary drain component, and (ii) said drain conduit; (i) installing said polymer sleeve intermediate said drain conduit and said internally threaded inner cylindrical opening; (j) providing a hollow externally threaded compression member shaped and dimensioned to turn into said internally threaded inner cylindrical opening of said primary drain component; (k) turning said compression member into said internally threaded inner cylindrical opening of said primary drain component to contact and compress said polymer sleeve between said drain conduit and said internally threaded inner cylindrical opening of said primary drain component; (l) providing at least one hollow cylindrical spacer with at least one drain opening formed therein; (m) securing said spacer to said flange of said primary drain component; (l) applying flooring to said upper surface of said base; (n) providing at least one hollow cylindrical shim; (o) securing said shim to said spacer to compensate for the thickness of said flooring; (p) providing a perforated drain cover; and, (q) mounting said drain cover on said shim. 